Horrible Noise
 

What do the cam-phasers sound like before they're ready to let go? I get a rattling noise at low idle when I start up the engine when it's hot. Let's say I drove 30 miles on the expressway, and then ran into the bank quick. When I come back out and start the truck up and cruise around the parking lot it rattles like a b***h. It's been doing this the past 5000 miles and has gotten progressively worse. When cold its always made a 2 second rattle upon startup which I believe is the lifters.

What oil filter are you using?

Could also be chain tensioner gasket bleeding pressure off, causing it to loose tension on the chains, you'd hear the chains clattering until oil pressure builds up

Motorcraft. Always Motorcraft. ;)

That makes sense. When once I get into the higher rpm range I don't hear it anymore. How serious is this?

My '07 does the same thing. This is from the VCT solenoids. Mine has done it since I first bought it 5 years ago at 42,000. Currently with over 130,000 miles, still does it. No issues from it. This is not timing chain noise, although it can make you think it is. Happens from 800-1,200 RPMs.

Ford has came out with an updated solenoid to help with this issue. Part # 8L3Z-6M280-B. It's not mandatory that you replace them unless they start causing problems with misfiring at idle.

That's not good. Sounds like classic oil starvation due to your flimsy timing chain tensioners ending up in the oil pan and clogging the oil pump pickup.

If you had caught that 5000 miles ago, the news would be better. Phasers need 25 PSI to operate and they haven't been getting that.

P.S. As you can guess, it's quite serious.

Mine has been doing it during the 90,000 miles I've owned mine. I also have the minimum hot 25 PSI after a long drive at hot idle in drive. Never has gotten louder. Just need to keep an eye on it. If it begins to get a rough idle, need to have it looked at. Rough idle is a sign of either low oil pressure or blocked oil passage, clogged solenoid screens, etc. Anywhere below 20 PSI is usually where things begin to go south.

Oh yeah. Had low oil pressure. No oil was getting to the top of the engine. Engine is now junk. Getting new one put in right now under warranty.

TSB 14-0114
06/03/14
5.4L 3V - INTERMITTENT RATTLE NOISE WHILE DRIVING / ROUGH
IDLE WHEN ENGINE IS AT OPERATING TEMPERATURE
FORD:
2004-2010 F-150
2005-2010 F-250, F-350
2005-2013 Expedition
LINCOLN:
2006-2008 Mark LT
2005-2013 Navigator
This article supersedes TSB 12-7-10 to update the vehicle model years and Service Procedure.
ISSUE
Some 2004-2010 F-150, 2005-2010 F-Super Duty 250/350, 2005-2013 Expedition, Navigator and 2006-2008 Mark LT vehicles equipped with 5.4L 3V engine may exhibit an intermittent rattle noise while driving from idle up to 1200 RPM when the engine is at operating temperature. In severe cases, a rough idle and diagnostic trouble codes (DTCs) P0022, P0021, P0340, and/or P0341 may be stored in the powertrain control module (PCM).
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Replace the left and right variable cam timing (VCT) solenoids. Refer to Workshop Manual (WSM), Section 303.